Simultaneous Enhancement of Welder Health and Aluminum Weld Joint Quality Using Controlled Welding Room Condition

Abstract

Aluminum alloy is crucial for lightweight and fuel-efficient vehicles due to its strength, lightness, and corrosion resistance. However, welding aluminum vehicle parts poses challenges, particularly porosity issues caused by trapped hydrogen gas in the weld metal. This study aimed to investigate the impact of the welding room environment on the health and properties of aluminum welding joints. To achieve this, an isolated room was created, where variations in airflow velocity (1.1 m/s, 1.6 m/s, and 2.1 m/s) and temperature (19 °C, 27 °C, and 35 °C) were implemented. The fume condition of the room was assessed to determine its impact on health aspects, while bead appearance and macrostructure were evaluated to assess weld joint quality. Results revealed that higher airflow velocity and temperature reduced fume concentration in the welding room, indicating a healthier environment. However, these conditions also led to increased porosity defects and influenced the performance of the shielding gas. Additionally, higher ambient temperatures increased hydrogen solubility in the molten aluminum, exacerbating porosity issues. For optimal welder comfort and high-quality weld joints, it is recommended to maintain a low temperature and airflow velocity in the welding room, ensuring a healthier working environment while minimizing porosity defects.